Packaging unit with ribs and method for packing products

ABSTRACT

The present invention relates to a packaging unit ( 2 ) with a label for products like eggs, and a method there for. The packaging unit according to the present invention comprises: a cover part ( 14 ) comprising top, front, side and rear surfaces; and a bottom part ( 4 ) comprising a number of compartments ( 26 ) for individual products, and a number of cones ( 28 ) that are positioned between adjacent compartments; wherein the bottom part comprising a number of ribs ( 34 ) extending between at least some of the compartments, wherein the bottom part further comprises a groove ( 48 ) between adjacent compartments, and wherein the grooves fire configured to receive part of the ribs of another packaging unit

The present invention relates to a packaging unit made of moulded pulpfor products like eggs and similar products like kiwis and tomatoes, forexample. Such packaging unit may also relate to cases, boxes, cups,plates, carriers, sip lids etc.

Egg cases, containers or cartons are known in practice and are generallyfabricated from carton made from moulded pulp originating from papermaterial. Such packaging units comprise a bottom part that is providedwith compartments for individual products, and a cover part that isoften hingedly connected to the bottom part. Eggs, or other products,are transported and displayed in these packaging units.

WO 2015/160248 A1 discloses a packaging unit comprising such bottom andcover part, and is provided with a hinge connecting both parts and alock that is configured for locking the cover part and the bottom partin a closed position of the packaging unit.

During transport, storage and display the packaging units are confrontedwith loads that may damage the packaging units and/or the productsinside these packaging units. To withstand these loads, conventionalpackaging units have to be provided with sufficient strength, therebyrequiring a certain amount of packaging material. This results in highpackaging costs.

The present invention has for its object to obviate or at least reducethe above stated problems in conventional packaging units such as eggcases or egg cartons, and to provide a packaging unit with improvedstrength and stability.

The present invention provides for this purpose a packaging unitaccording to the invention from a moulded pulp material for productslike eggs, the packaging unit comprising:

-   -   a cover part comprising top, front, side and rear surfaces; and    -   a bottom part comprising a number of compartments for individual        products, and a number of cones that are positioned between        adjacent compartments;

wherein the bottom part comprising a number of ribs extending between atleast some of the compartments, wherein the bottom part furthercomprises a groove between adjacent compartments, and wherein thegrooves are configured to receive part of the ribs of another packagingunit.

Having a packaging unit with a bottom part and a cover part made ofmoulded pulp enables transport and display of products without damagingthe products. This is especially relevant in case of vulnerable productslike eggs. This is also relevant in the transport of empty packagingunits that often takes place in stacks of packaging units in an openposition.

In a preferred embodiment, the cover part is hingedly connected to thebottom part on the rear side thereof. On at least the front side of thepackaging unit a lock is provided comprising a first locking element onthe bottom part, such as a cam or edge, and a second locking element inthe cover part, such as an opening, that is configured for receiving thefirst locking element.

The cone shaped element (partly) separates adjacent compartments andpreferably supports the product(s). The cone shaped element may comprisea cone and/or equivalent separator between adjacent compartments.

According to the invention the bottom part further comprises a groovebetween adjacent compartments, wherein the grooves are configured toreceive (at least a) part of the ribs of another packaging unit.Providing a groove enables improvement of the stacking stability ofpackaging units in an open position. Packaging units are often storedand/or stacked in open position before being filled with the product(s).Due to the groove being configured for receiving the rib, or at least apart of such rib, provides an aligning effect and an improved stability.Preferably, the groove is configured such that a clamping force acts ona rib that protrudes the groove. Experiments showed that even a smallclamping force increases the stability of a stack without hindering thehandling operation of the packaging units. This improves storage andtransport of (empty) packaging units.

In a presently preferred embodiment of the invention at least theadjacent compartments at the sides of the packaging unit are providedwith a groove.

Experiments have shown that especially the provision of grooves betweenadjacent compartments on the sides of the packaging unit provide animproved stability to the packaging unit, also in an open position ofthe packaging unit in a stack of packaging units.

Preferably, the grooves are configured to support the ribs of anotherpackaging unit in a stack of packaging units. Especially in a stack ofpackaging units in an open position this improves the stability of thestack. More preferably, the shape of the grooves substantiallycorresponds to the shape of the (part of) the rib that is received andsupported in the groove.

In a presently preferred embodiment of the invention the bottom partfurther comprises a number of ribs extending between at least some ofthe compartments, and wherein the ribs are provided with a V-shapedcross-section.

Providing ribs between adjacent compartments with a V-shapedcross-section increases the strength of the packaging unit. This is alsoan advantage for a stack of packaging units. For example, a stack maycomprise more packaging units without damaging the (lower) packagingunits in the stack. This reduces storage, transport and/or handlingcosts of the packaging units.

Furthermore, the V-shape provides a self-seeking or self-aligning effectwhen stacking packaging units according to the invention. This rendershandling, specifically stacking, of the packaging units easier. As afurther effect denesting of the packaging units is easier. This furtherimproves handling op the packaging units, specifically the stacking andunstacking thereof. Preferably, the ribs have a height in the range of5-12 mm, more preferably in the range of 6-10 mm, and most preferably inthe range of 7-8 mm.

In a presently preferred embodiment of the invention the ribs areprovided with a V-shape in length direction of the ribs.

Providing ribs with a V-shaped in length direction of the ribs furtherincreases the strength of the packaging unit. The V-shaped rib as seenin length direction of the ribs are preferably applied in combinationwith the V-shaped cross-section of the ribs. Experiments showed relevantincrease in strength and easier stacking involving nesting and denestingof the packaging units. It will be understood that the V-shaped ribs canalso be applied independently from the other features in packagingunits.

In a presently preferred embodiment the ribs connect to the compartmentsat a height of more than 4 mm above the ground surface as defined by thebottom side of the bottom part.

Providing elevated ribs surprisingly improves the strength and stabilityof the packaging units. This reduces the risk of undesired bending andtorsion of the packaging unit. Preferably the connection height is above4 mm, more preferably above 4.5 mm, and most preferably about 5 mm. Alsopreferably, the connection height is below 20 mm, more preferably below15 mm, and most preferably below 10 mm.

A further effect of the application of the aforementioned height is theimproved gripping of the packaging unit with grippers in the packingoperation. This improves handling of the packaging unit when packingwith products.

In a presently preferred embodiment of the invention at least a numberof ribs extending in width direction of the packaging unit, such thatthe ribs extend substantially perpendicular to the front surface of thebottom, have a width of more than 0.9 mm, preferably more than 0.9 mm,and most preferably more than 1.0 mm.

By increasing the width of the ribs, seen in a substantially paralleldirection with the front surface, the torsion resistance issignificantly improved. This provides additional stability to thepackaging unit. This width is preferably applied in combination with theV-shape of the ribs in width and/or length direction of the rib(s),and/or with the aforementioned elevated connection of the rib(s).

In a presently preferred embodiment of the invention the compartmentscomprise a bottom with an elevated portion, wherein the bottom of theelevated portion is provided with a convex shape.

Providing elevated portions provides the compartments with an additional“bumper” effect that improves the protection of the products. Providingthe bottom of the elevated portion with a convex shape preventsundesired moving of the packaging units when being transported over aconveyor belt, or other transporting means. This provides a more stableposition of the packaging units during transport that is typically anadvantage when putting the products in the packaging unit. Preferably,the convex bottom shape of the elevated portions resembles a sphericalor dome shape.

Preferably, the convex shaped bottom of elevated portions in thecompartment is applied in combination with the V-shaped ribs are appliedand/or the cones having one or more openings that are also presented inthis description. This combination of openings and cones having one ormore openings improves the strength of the packaging unit, whilereducing material and drying costs. It will be understood that theconvex shaped bottom of elevated portions can also be appliedindependently from the other features in packaging units.

In a presently preferred embodiment of the invention the bottom partcomprises a number of denest-elements having a height in the range of2-7 mm, preferably 3-6 mm.

Providing denest-elements improves denesting the packaging units from astack. In a preferred embodiment the denest-elements have a height inthe aforementioned range. This reduced height reduces the so-calledstacking pitch of the packaging units. This has as an advantageouseffect a shorter bundle length thereby preventing, or at least reducing,the overhang so that the packaging units better fit on a pallet, forexample.

In one of the presently preferred embodiments of the invention at leastsome of the cones are provided with openings that are configured toenable a gas stream to pass through the opening.

Providing an opening in the cone enables a gas flow, preferably an airflow, through the cone. In the manufacturing process this significantlycontributes to the drying process of the packaging unit. Therefore, thedrying of the packaging unit is significantly improved. In addition, thedrying operation of the packaging unit is more controlled and/orgradually. The improved drying increases the strength of the packagingunit without increasing the required amount of material and/or reducesthe amount of material, while maintaining the strength of the packagingunit.

A further effect of providing the cones of the packaging units with oneor more openings is the reduced overall weight of the packaging unit.This reduces the material costs, and may reduce drying costs and/or mayimprove handling of the packaging unit. For example, for a standard eggpackage the weight reduction may amount to about 1 gram.

As a further effect of providing the cones of the packaging unit withone or more openings is the reduction in product damage during storage,transport and/or display. This is specifically relevant for vulnerableproducts like eggs. The increased strength of the packaging unittherefore reduces product loss.

In a presently preferred embodiment of the invention the openings havean effective diameter in the range of 0.5-15 mm, preferably in the rangeof 1.0-10 mm, more preferably in the range of 2.0-8 mm, and mostpreferably in the range of 3-6 mm.

Experiments showed that providing openings with the effective range inthe mentioned range achieves an increased strength due to the improveddrying operation. The openings are preferably shaped as a circle havinga diameter. This diameter corresponds to the effective diameter. It willbe understood that other shapes for an opening are also possible. Forexample, the opening may be an ellipse. In such case the effectivediameter corresponds to the diameter of a circular opening having anequal opening surface.

In a presently preferred embodiment of the invention at least some ofthe openings are provided at or close to the top of the cone.

Providing at least some of the openings at or close to the top of thecone achieves an effective drying operation. This further enhances thestrength of the packaging unit.

Preferably, V-shaped ribs are applied in combination with the coneshaving one or more openings. This combination of openings and coneshaving one or more openings improves the strength of the packaging unit,while reducing material and drying costs.

In a presently preferred embodiment of the invention the moulded pulpmaterial comprises an amount of natural fibers. Additionally, oralternatively, the moulded pulp material comprises an amount of abiodegradable material.

The application of natural fibers and/or biodegradable material, such asan aliphatic polyester, is described in WO 2018/067006 A1 of the sameapplicant. The use of natural fibers and/or biodegradable materialresults in packaging units that are substantially NIOSH and/or MOAHfree, and/or are (home) compostable. These materials are preferablyapplied in combination with one or more of the aforementioned features,especially the cone having one or more openings, and the V-shaped ribsand/or bottom shape of the elevated portions of the compartments. Suchcombination provides additional strength to the packaging unitsproviding more possibilities to use alternative materials withoutreducing the behavior of the packaging units.

The present invention further relates to a method for packing productslike eggs, comprising the steps of providing a packaging unit asdescribed above, and placing therein one or more of the products.

Such method provides the same effects and advantages as described withrespect of the packaging unit.

Further advantages, features and details of the invention are elucidatedon a basis of preferred embodiments thereof, wherein reference is madeto the accompanying drawings, in which:

FIG. 1 shows a 3-dimensional view of a packaging unit according to theinvention;

FIG. 2A shows a top view of the packaging unit of FIG. 1 in an openposition;

FIGS. 2B-D show a side view and two cross-sections of the packaging unitof FIG. 2A, respectively;

FIGS. 2E-F show views of the bottom and top parts of the packaging unitof FIG. 2A in the open position, respectively;

FIGS. 3A-D show top, front, side and bottom view of the packaging unitof FIG. 1 in a closed position, respectively; and

FIGS. 4A-B a 3-dimensional view of an alternative packaging unit with 10compartments;

FIGS. 4C-D a 3-dimensional view of a further alternative packaging unitwith 12 compartments; and

FIGS. 4E-F a 3-dimensional view of an even further alternative packagingas a twin-pack.

A packaging unit 2 (FIG. 1 ) comprises bottom part 4 with front surface6, two side surfaces 8, rear side 10, and bottom side 12. In theillustrated embodiment, cover part 14 is hingedly connected with hinge16 to bottom part 4 to allow cover part 14 to move relatively to bottompart 4 between an open (FIG. 2A-F) and a closed (FIG. 3A-D) position.Cover part 14 further comprises front surface 18, two side surfaces 20,rear side 22 and top surface 24.

On the inside of bottom part 4 (FIGS. 1 and 2A-F) product receivingcompartments 26 are provided having contours matching at least partiallythe outer contours of the products, like eggs, kiwis and tomatoes, forexample. Support cones 28 are provided to add stability and strength topackaging unit 2.

Cones 28 are provided with opening 30. In the illustrated embodimentopening 30 is provided at the top of cone 28. It will be understood thatadditional openings and/or alternative positions can also be envisagedin accordance to the present invention. In the illustrated embodimentopening 30 has an (effective) diameter of about 5.6 mm it will beunderstood that other sizes and shapes of opening 30 can also beenvisaged in alternative embodiments of the invention. Opening 30provides channel 32 in or through cone 28 to enable a gas flow throughcone 28, especially during drying.

Ribs 34 (FIGS. 1-3 ) are provided between adjacent compartments 26. Ribs34 have a V-shaped cross-section and a V-shape when seen in lengthdirection of rib 34 between two adjacent compartments 26. Ribs 34connect to compartments 26 at a height H above the ground surface asdefined by bottom side 12 of bottom part 4. In the illustratedembodiment height H is about 5 mm. Providing height H enables grippersto grip packaging unit 2. This improves handling of packaging unit 2. Inthe illustrated embodiment ribs 34 have a height of about 7.5 mm. Testsshowed an effective increase of the overall strength of packaging unit2.

Compartments 26 of bottom part 4 have support surfaces 36 compriseelevated bottom 38 having a spherical shape. Denest elements 40 a incover part 14 are provided having a height of about 6-8 mm. Denestelements 40 b in bottom part 4 are providing having a height of about3-6 mm extending from edge 41. Optionally, a label (not shown) isprovided to one or more of the surfaces of packaging unit 2.

Lock 42 comprises opening 44 in cover part 14 and nose shaped cam 46 ofbottom part 4. Cam 46 is provided on flap 49 that is hingedly connectedby connection 50 to bottom part 4 of packaging unit 2. Optionally, cam46 defines a closed outer surface or outer contour defining a chamber.In the illustrated embodiment the substantially downward facing surfaceof cam 46 may contact opening 44 to achieve lock 42. In the closedposition of packaging unit 2 (FIG. 3A-D), cam 46 partly extends throughopening 44 that is provided in the front surface 18 of cover part 14.The upper edge of opening 44 is optionally provided at a small angle andis slightly pushed inwards. It will be understood that according to theinvention other locks may also be applied.

When packing products like eggs, the products are placed in compartments28. In the illustrated embodiment, when cover part 14 is closed lock 42with locking elements 44, 46 locks packaging unit 2. In the illustratedembodiment, in such closed position cam 46 partly extends and protrudesthrough opening 44 of front surface 18 of cover part 14.

Grooves 48 are provided in bottom part 4. Grooves 48 are configured toreceive part of ribs 34. Grooves 48 are optionally provided between alladjacent compartments 26. In the illustrated embodiment grooves 48 arespecifically (and only) provided between the two outer compartments 26′at the sides of bottom part 4.

In the illustrated embodiment packaging unit 2 has a length L in aclosed position (FIG. 3A-D) of about 247 mm, a width W of about 107 mm,and a height H_(p) of about 68 mm. It will be understood that otherdimensions are also possible and may depend on the number ofcompartments 26 in packaging unit 2. Packaging unit 2 is made of amoulded pulp material that optionally comprises a biodegradable materialsuch an aliphatic polyester, for example PLA, PBS. Also optionally, themoulded pulp material may comprise an amount of natural fibers such asgrass fibers. Further examples of biodegradable materials and/or naturalfibers are described in WO 2018/067006 A1 of the same applicant.

In the manufacturing process packaging units 2 are formed from mouldedpulp. After forming packaging units 2 are dried. Opening 30 in cones 28enable a gas flow through channel 32, thereby improving the dryingprocess.

It will be understood that packaging unit 2 having ten productcompartments can also be provided as a related packaging unit withanother number of product compartments. For example, similar packagingunits having twelve product compartments or twin pack units having twopackaging units with each 6 product compartments. Also, these relatedpackaging units can be provided in a similar design having the same orat least similar features as shown for packaging unit 2.

Alternative packaging unit 102 (FIG. 4A-B) comprises bottom part 104with front surface 106, two side surfaces 108, rear side 110, and bottomside 112. In the illustrated embodiment, cover part 114 is hingedlyconnected with hinge 116 to bottom part 104 to allow cover part 114 tomove relatively to bottom part 104 between an open (FIG. 4B) and aclosed (FIG. 4A) position. Cover part 114 further comprises frontsurface 118, two side surfaces 120, rear side 122 and top surface 124.

On the inside of bottom part 4 (FIG. 4B) product receiving compartments126 are provided having contours matching at least partially the outercontours of the products, like eggs, kiwis and tomatoes, for example.Support cones 128 are provided to add stability and strength topackaging unit 2. In this embodiment support cones 128 are provided withclosed top 130.

Ribs 134 are provided between adjacent compartments 126 and have aV-shaped cross-section and a V-shape when seen in length direction ofrib 134 between two adjacent compartments 126. Ribs 134 connect tocompartments 126 at a height H above the ground surface as defined bybottom side 112 of bottom part 104. In the illustrated embodiment heightH is about 5 mm. Providing height H enables grippers to grip packagingunit 102. This improves handling of packaging unit 102. In theillustrated embodiment ribs 134 have a height of about 7.5 mm. Testsshowed an effective increase of the overall strength of packaging unit102.

Compartments 126 of bottom part 104 resemble compartments 26 as shownfor packaging unit 2. Also lock 142 resembles lock 42 as shown forpackaging unit 2. It will be understood that according to the inventionother locks may also be applied. Grooves 148 are provided in bottom part104. Grooves 148 are configured to receive part of ribs 134. Grooves 148are optionally provided between all adjacent compartments 126. In theillustrated embodiment grooves 148 are specifically (and only) providedbetween the two outer compartments 126′ at the sides of bottom part 104.Dimensions and/or materials are similar to the dimensions and/ormaterials described in relation to packaging unit 2.

Packaging unit 202 (FIG. 4C-D) is provided with twelve compartments 126.Other features are the same or similar to that of packaging unit 102having ten compartments 126.

Packaging unit 302 (FIG. 4E-F) is provided as a so-called twin-packhaving two connected (sub)packaging units each having 6 productcompartments.

Alternative packaging units according to the invention may hold otherproducts, like kiwi's, eggs, tomatoes, apples etc. and/or also ahamburger, salad etc.

The present invention is by no means limited to the above described,preferred embodiments thereof. The rights sought are defined by thefollowing claims, within the scope of which many modifications arepossible.

1. Packaging unit from a moulded pulp material for products like eggs,comprising: a cover part comprising top, front, side and rear surfaces;and a bottom part comprising a number of compartments for individualproducts, and a number of cones that are positioned between adjacentcompartments; wherein the bottom part comprises a number of ribsextending between at least some of the compartments, wherein the bottompart further comprises a groove between adjacent compartments, andwherein at least one of the grooves is configured to receive at leastpart of one of the ribs of another similar packaging unit.
 2. Packagingunit according to claim 1, wherein at least the adjacent compartments atthe sides of the packaging unit are provided with a groove.
 3. Packagingunit according to claim 1, wherein the grooves are configured to supportthe ribs of another packaging unit in a stack of packaging units. 4.Packaging unit according to claim 1, the ribs are provided with aV-shaped cross-section.
 5. Packaging unit according to claim 1, whereinthe ribs are provided with a V-shape in a length direction of the ribs.6. Packaging unit according to claim 1, wherein the ribs connect to thecompartments at a height of more than 4 mm above the ground surface asdefined by the bottom side of the bottom part.
 7. Packaging unitaccording to claim 1, wherein at least a number of ribs extend in awidth direction of the packaging unit, such that the ribs extendsubstantially perpendicular to a front surface of the bottom and have awidth of more than 0.9 mm.
 8. Packaging unit according to claim 1,wherein the compartments comprise a bottom with an elevated portion,wherein the bottom of the elevated portion is provided with a convexshape.
 9. Packaging unit according to claim 1, wherein the bottom partcomprises a number of denest-elements having a height in the range of2-7 mm.
 10. Packaging unit according to claim 1, wherein at least someof the cones are provided with openings that are configured to enable agas stream to pass through the opening.
 11. Packaging unit according toclaim 10, wherein the openings having an effective diameter in the rangeof 0.5-15 mm.
 12. Packaging unit according to claim 10, wherein at leastsome of the openings are provided at or close to the top of the cone.13. Packaging unit according to claim 1, wherein the moulded pulpmaterial comprises an amount of natural fibers.
 14. Packaging unitaccording to claim 1, wherein the moulded pulp material comprises anamount of a biodegradable material.
 15. Method for packing products likeeggs, comprising the step of providing a packaging unit according toclaim 1, and placing therein one or more of the products.